Apparatus for the automatic horizontal assembly of photovoltaic panels

ABSTRACT

A plant and system for the automatic horizontal assembly of photovoltaic panels with front-back-contact solar cells of crystalline silicon, of the type called H-type, the contacting being carried out at a temperature lower than 150° C. also with the pre-fixing of conductive elements onto the encapsulating layer. The plant and system solve the main problems of the conventional stringing systems and provides high production capacity with a precise positioning of the components. The plant is made up of single workstations of the modular type which are arranged sequentially in a linear series, individually equipped according to the specific working process, being adjacent and laterally open to be crossed by the conveying line of the trays containing the panels being worked. After the automatic assembly in the plant, the panels are ready to be rolled in conventional furnaces.

CROSS-REFERENCE TO RELATED U.S. APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

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REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC

Not applicable.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a plant and system for the automatichorizontal assembly of photovoltaic panels having solar cells ofcrystalline silicon of the H-type, with the front-back connection of thecells carried out at low temperature and with pre-fixing; said plant andsaid system, being particularly of the automatic type with highproduction capacity and great precision and accuracy in the positioningof the components.

2. Description of Related Art Including Information Disclosed Under 37CFR 1.97 and 37 CFR 1.98

The invention finds particular application in the industrial sector ofproduction of photovoltaic panels, with specific reference to the panelsof first generation with cells of monocrystalline or polycrystallinesilicon having the electrical contacts of opposite polarity placedrespectively on the front and on the back of the cell, also calledH-type, also with the modern evolutions of such cells, such as the cellsof the hetero junction type also known by the acronym HIT™ or HJT.

The basic components of a panel having an H-type architecture startingfrom the back side not exposed to the sun substantially are: a backlayer of support and protection from the weather, also called backsheet;said photovoltaic cells of monocrystalline or polycrystalline silicon;the longitudinal interconnection ribbons intended to weld in series twoby two the front and the back of adjacent cells; the conductive crossribbons at the head and at the bottom of the panel, for the generalconnection in series of said longitudinal ribbons with interposed diodesin the junction box; two layers of encapsulating material, generallyethylene vinyl acetate or EVA, intended to enclose at the front and atthe back said cells with said interconnecting ribbons and cross ribbons;a flat glass which encloses and protects the front side of the panel,exposed to the sun; a frame which encloses the perimeter of the panel;said junction box being placed on the back side of said backsheet, forthe purpose of collecting the contacts from the back connecting to saidcross ribbons. For example, see the tables of the known prior art (FIGS.1, 2).

This configuration of a photovoltaic panel today is the best known andmost widespread on the market; however, it has been observed that theprocess of assembly of such a panel solution is slow and imprecise as itis carried out mostly manually, except for the welding of saidinterconnecting ribbons to the cells. The process generally provides tostart the assembly of the components from the front glass placed on ahorizontal plane, on which an encapsulating layer of EVA issuperimposed, then the stringing on the front and on the back of thesingle cells by welding, then the positioning of all the conductiveelements with the following welding between interconnecting ribbons andcross ribbons, the visual inspection, the positioning of the backencapsulating layer and of the supporting backsheet, the rolling in thefurnace for fixing and encapsulating the components and, then, the finalassembly of the junction box and frame.

Furthermore, it has been observed that the conventional technologies ofelectrical interconnection of the cells on the front and on the back,although made by automated welding procedures, can be widely improveddue to the known problems of discontinuity in the adhesion and thereforein the resistance of contact, of deformation, of differentiated thermalexpansion with consequent residual stresses and due to some productionand quality problems, described in the following.

In more detail as to the architecture of said cells of the H-type, ithas been observed that some improvements have been recently introduced,which are intended to facilitate said welding phase and also to improvethe collection efficiency of the photovoltaic currents by means ofinnovative solutions of surface metallization to form the electrodes.Traditionally, the main conductive elements present on the front side ofthe cell, called busbars, are generally placed in a parallel way andspaced from each other to collect the currents of electrons picked upsuperficially by the thin conductive elements arranged orthogonally,called fingers, for the purpose of conveying them by means of saidinterconnecting ribbons to said cross ribbons at the head and bottom ofthe panel; the conduction of said currents from said front busbars ofeach cell to the busbars of opposite sign placed on the back of theadjacent cell is obtained by means of interconnecting ribbons welded incorrespondence of each front and back busbar on both faces of the samecell, progressively realizing an interconnection in series of thefront-back type between the cells, from the bottom to the head of thepanel, in such a way as to convey all the currents of the string ofcells to the back junction box. For example, see the tables of the knownprior art (FIGS. 3a-b ). Today, with respect to the traditionalsolutions of cell with two continuous and parallel busbars on eachfront, more efficient solutions of surface metallization are availableon the market, which are based on a greater number of busbars, forexample three or four on each front; furthermore, particular improvementsolutions are also known with busbars of the discontinuous type, in theform of hatched pads interconnected to each other, which enable awelding of the punctual type which is more economical in the productionprocess and also solves some known problems, described in the following.

In more detail as to the conventional technologies of electricalinterconnection of the cells, it has been observed that the welding ofan interconnecting ribbon on the front busbar of the cell and on thecorresponding back busbar of the adjacent cell, is one of the mostdelicate and complicated phases of the whole assembly process of aphotovoltaic panel with H-type architecture; such a production phase isindustrially carried out by means of automatic devices of mediumcomplexity, called automatic stringers, which have some known problemsdescribed in the following. As an alternative to said automaticstringing, today widespread are production systems in which such weldingis carried out manually with a consequent waste of time, inaccuracy orpoor repeatability and a low level of quality of the final result.

Among the known solutions intended to solve the problems ofinterconnection of the cells or to improve the production processes ofthe panel some innovative solutions of a cell with discontinuous busbarscan be pointed out, as for example in US2010000602 (Gray et al.),US2009277491A1 (Nakamura et al.) and WO2012140139 (Von Campe et al.) oreven the known solutions of back-contact cells of new generation, whichare insulated like conductive pads. Furthermore, as to the cells of theH-type, we would like to recall the technologies of electricalinterconnection at high temperature alternative to conventional weldingsuch as induction heating as in EP2607008 (Meisser et al.). In moredetail, we recall the use of the conductive adhesives of the type calledElectrically Conductive Adhesive or conventionally known by the acronymECA, which are widely used in the industrial sector of electronics andwhich also are used in the photovoltaic panels of new generation havingback-contact cells, as for example in EP2139050 (Bakker et al.).Furthermore, one should remember the recent solutions of panels withstandard front-back-contact cells which are interconnected by means ofconductive adhesives; for example, see the solution proposed inUS20110048492 (Nishiwaki) where the conductive elements are joined atlow temperature with a conductive resin of the soft type which preventscracks and decreases surface stress on the cell, or see the solutionproposed in WO2013048758 (Clark et al.) where the adhesive has aparticular composition and a specific transition temperature, or stillsee the solution as in WO2013110607 (Martini et al.) where the busbarsare pre-treated in such a way as to facilitate adhesion. As a furtherexample, one should remember the known solutions of automatic stringersas in WO2013068982 (Knoll et al.) or WO2010031571 (Schartl et al.).

For the purpose of determining the prior art related to the proposedsolution a conventional check was made, searching public archives, whichhas led to find some prior art documents, among which:

-   D1: ITTV2012A000211 (Baccini et al.)-   D2: U.S. Pat. No. 8,253,009 (Reinisch)-   D3: WO2010000812 (Merz et al.)-   D4: U.S. Pat. No. 8,485,774 (Knoll et al.)-   D5: DE102008046327 (Kalmbach et al.)-   D6: WO03098704 (Dings et al.)-   D7: WO2008145368 (Reinisch et al.)

D1 proposes a plant and a method for the automatic assembly ofphotovoltaic panels with back-contact cells, said cells beinginterconnected with adhesives of the ECA type on the back side only, incorrespondence of the conductive layer of a particular backsheet whichalso integrates the encapsulating and the dielectric material; such abacksheet, previously made, is placed horizontally on a tray with theconductive layer facing upwards and with the areas of contacting of thecells already masked in such a way as to allow the laying of theconductive adhesive with automatic drop-by-drop dispensing as well aswith the control of the position; then one lays the cells, the upperlayer of encapsulating material and the glass, which will then besubjected to conventional rolling.

D2 describes a solar cell connecting apparatus having operating modules,of which a first module is for joining the solar cells and stripstogether, a second module is for soldering the strips to the solarcells, and a third module is for transporting them through the othermodules; the system includes a continuous system for positioning theconductive elements suitable for standard cells as well.

D3 proposes a system and a method for the production of photovoltaicpanels with standard cells wherein the handling of the cells issimplified being placed in aligned rows and connected by means of sidecontacting elements.

D4 describes a high productivity apparatus consisting of a plurality ofstringers arranged perpendicularly, or at an acute angle, with respectto the conveyor belt which moves the strings to the centralinterconnection station where the complete matrix is made, the apparatusbeing controlled by a camera vision system and managed by the centralcontrol system.

D5 proposes a plant and a method for the production of photovoltaicpanels which comprises at least one device for the preparation of thesupport, one device for the pre-assembly of the cells, one device forthe positioning of the cross contacts on the substrate, one device forthe loading of the pre-assembled cells, one device for the contacting ofthe cells, one device for closing the circuits of the strings and onedevice for fixing the components to the supporting glass.

D6 describes a compact station of preparation of the cells with theapplication of the connecting conductive elements, and it also proposesa following stringing station which is intended to form the completepanels on the transparent glass, the contacting being carried out bywelding or by laser without contact.

D7 proposes an assembly station structured with two parallel workinglevels: an upper level for the cells and a lower level for thetransparent glass, the preparation of the cells being separated into twoadjacent tracks, which join each other to couple with the underlyingglass in a laser welding station, the movement devices being comprisedin the overall dimensions of the aligned devices that form theproduction line.

In conclusion it is reasonable to consider as known:

-   -   a photovoltaic panel of first generation with cells of the        standard type called H-type, with front-back contacting,        enclosed between two layers of encapsulating material and        assembled in a mainly manual way;    -   a cell of the standard type with front collection fingers and        contacting busbars placed on the front and on the back of the        cell which are of the continuous or discontinuous type;    -   a stringing system of the standard cells at high temperature        with inserted conductive elements which are welded first on one        side and then on the other side, turning the cell, or by laser        through a transparent glass, or even by induction;    -   a stringing system of the standard cells at low temperature with        particular conductive adhesives;    -   a contacting system of the cells of the back-contact type,        directly on a conductive backsheet only on the back side of the        cells, by means of drop-by-drop dispensing of ECA adhesive;    -   a system and a process for the stringing of standard cells by        welding, laser or induction;

Drawbacks

In conclusion, we have observed that all the known solutions havedrawbacks or anyway some limits.

Generally, in the panels of first generation with cells of crystallinesilicon of the standard type, with front-back contacting, it is widelyknown that the conventional processes of welding of the strings of cellsoften imply quality problems with a high probability of breaking, highcontact resistance and/or variable from one cell to the other and intime, wear of the cells, limited duration in time or due to the weather,thus obtaining a high efficiency loss from the cell to the module, alsocalled cell-to-module loss, which typically reaches absolute valuesbetween 2% and 5% of the total conversion efficiency.

In more detail as to the conventional solutions of electricalinterconnection of said cells of the standard type, it has been observedthat the quality of said interconnection depends in a decisive way onthe number and on the shape of said interconnecting ribbons; for thepurpose of realizing said interconnection correctly, in fact, it isnecessary to continuously interpose between one cell and the other ahigh number of said conductive elements, which must have such athickness and width as to allow the transport of all the electriccurrent generated by each cell. In principle it would be desirable, withan equal overall section of said interconnecting ribbons, to provide ahigh number of said conductive elements, each one being provided withsmall width and great height for the purpose of reducing the shading onthe cell and increasing the collection of the electrical chargesgenerated by photovoltaic effect; however, the width of saidinterconnecting ribbons is limited by the difficulty of the weldingoperation which increases when the width decreases and the contactresistance increases. The increase in height of said interconnectingribbons, too, is limited by the evident technological and physicallimits and it also implies greater thicknesses of the frontencapsulating layer, with consequent irradiation losses. The maximumnumber of interconnecting ribbons which can be interposed on the frontof each cell is instead limited by the dimensions and by the design ofthe stringers themselves; to this purpose, it has been found that todayit is industrially difficult, and thus limiting, to exceed the number offour or five interconnecting ribbons on each face of the cell. From whathas been described above derives a remarkable variability of the contactresistance between said cells and said interconnecting ribbons, which asa consequence is translated into said cell-to-module loss which isvariable from one module to the other but which in any case is of arelevant value and negatively affects the quality and performances ofthe finished product.

A second problem that has been found lies in the need to keep an averagehigh temperature, generally between 200° C. and 300° C., over the wholesurface of each of said interconnecting ribbons; in fact, it is wellknown that such a temperature is critical as to the correct melting ofthe alloy that covers the conductive element, for the purpose ofcoupling with the related busbar. Said temperature, in particular, istoo high for some constructions of photovoltaic cell such as said heterojunction silicon cells called HIT™ or HJT; such cells, in particular, donot allow during welding to exceed the temperature of about 180° C.because of the particular production processes. In general and inprinciple, it is also known that the higher the temperature is to whichthe cells are subjected after the production phase called firing, andespecially in the presence of statuses of joint tension as it alsooccurs during the stringing phase, the greater is the probability thatdamage to the cell occurs.

A third problem that has been found concerns the need to keep ahomogenous temperature on the entire welding surface of saidinterconnecting ribbons, in order to prevent differences anddiscontinuities of the contact resistance, this being a characteristicthat strongly affects the electrical performances of the whole panel.

A fourth problem that has been found concerns the risk of breaking ofthe cells; having to transfer a considerable amount of heat, generallyby contact, the stringers must make a pressure on the ribbons during theheating that, due to the intrinsic fragility of the solar cells ofcrystalline silicon and often due to their bending caused by thedifferential shrinkage between the two opposite faces of the same cellon which different quantities of metal are laid, this is translated intoa high probability of breaking of the cells themselves. It is known thatthis probability varies from one manufacturer to the other, being onaverage between about 0.5% and 1% of the total of the stringed cells.

A fifth problem that has been found concerns adhesion; in fact, sincethe ribbon has to adhere as best as possible onto a large surface of thecell, a sufficiently wide area is necessary for the coupling by weldingwith the ribbon itself; said area must be metallized, forming saidbusbars, and commonly sintered with the crystalline matrix of thesilicon underlying the layer of silicon nitride laid on the surface tomake the so-called anti-reflection layer. Therefore, conventionalstringing requires that the surface of said busbars is sufficientlylarge and this is expensive because the metallization material of saidbusbars is essentially silver; for example, we have observed that thisvaluable material is generally present in the metallization paste in apercentage on average between 85% and 92% of the total weight of thepaste itself.

A sixth problem that has been found in conventional solutions concernsthe balancing of the strains and of the deformations between the upperface and the lower face of the cell. During the stringing phase, infact, weldings are alternatively carried out on both faces of the samecell, for the purpose of enabling the connection between the oppositeelectrical polarities of adjacent cells. In particular, it has beenobserved that this operation requires high temperatures, generallyincluded between 200° C. and 300° C., which imply differential thermaldeformations between the different materials forming the cells and theribbons which cause residual tensions in these materials; in fact, it isknown that such tensions can jeopardize the integrity of the cellsduring the stringing phase, during rolling or even during operation. Forthe purpose of minimizing said strains and said deformations it isdesirable to balance exactly what is made on the front face with whatoccurs on the back face of the same cell, however said balancing beingof difficult realization, the higher the temperature is to which thestringed cell is subjected.

Furthermore, as to the assembly process of a panel with conventionalstringing, it has been observed that the cells and said interconnectingribbons need extreme precision and regularity in laying in order to beable to be correctly welded in electrical series; such components,moreover, are interposed between two layers of encapsulating material,like the known thermoplastic materials of the EVA type or polyolefins,and also enclosed between the front glass and said backsheet, for thepurpose of prearranging the multi-layer panel for the final operation ofrolling in the furnace, which occurs at about 150° C. In particular,since in most cases such operations are performed manually, it is wellknown that they involve a large use of workforce, time and the risk offaults with frequent and expensive reprocessing. Moreover, for thepurpose of ensuring that the cells and said ribbons do not undergorelative translations during the whole process described, damaging theappearance and the functionality of the strings, said components fromtime to time are fixed with adhesive tapes applied manually, which arean additional cost. Therefore, it has been observed that therepeatability, the regularity and the guarantee of the quality of thefinished product are strongly affected by the manual skills and by theexperience of the many operators who carry out the various assemblyphases.

Said problems of interconnection of the cells and of assembly are oftenthe cause of defective panels with consequent economic damage due towastes or reprocessing, if the faults are found during production; inparticular, it is known that the faults concerning the electricalcontacting of the cells are particularly serious as they are difficultto find, if not after the final rolling phase, that is to say, when thepanel is already damaged and unrecoverable. Furthermore, we haveobserved that the residual tensions inside the cells caused by theconventional stringing processes can sometimes lead to the breaking ofthe cell itself, said breaking also being able to occur long after theinstallation in operation of the panel.

Furthermore, as to the known solutions of panels with a back-contactarchitecture, it has been observed that the innovative integrated andautomated solutions of horizontal assembly today are linked to cellswhich are still not widespread on the market, not being instead suitablefor the conventional cells of the H-type which must be welded on thefront and on the back in correspondence of said busbars.

Hence the need for the companies of the sector to find solutions whichare more effective with respect to the existing solutions; the aim ofthe present invention is also to solve the described drawbacks.

BRIEF SUMMARY OF THE INVENTION

This and other aims are achieved by the present invention according tothe characteristics as in the appended claims, solving the arisingproblems by means of a plant (10) and a system for the automatichorizontal assembly of photovoltaic panels (30) with solar cells (300-1)of crystalline silicon with front-back contacting, of the type calledH-type, the contacting being carried out at a temperature lower than150° C. also with the pre-fixing of conductive elements on theencapsulating layer; the invention solves the main problems of theconventional stringing systems and also enables a high productioncapacity with precision of positioning of the components. The plant (10)is made up of single workstations (100A-I) of the modular type which aresequentially placed in linear series, and which are individuallyequipped according to the specific working process, being adjacent andlaterally open to be crossed by the conveying line (110) of the trays(109) containing the panels being worked; after the automatic assemblyin said plant (10), the panels are ready to be rolled in conventionalfurnaces.

Aims

In this way by the considerable creative contribution the effect ofwhich has allowed to reach a considerable technical progress, some aimsand advantages are achieved solving the main drawbacks pointed out.

A first aim of the invention was to prevent the occurrence of the faultsgenerally connected with the assembly process and particularly to theelectrical connection of the cells, eliminating the causes of wastes orreprocessing due to the manual working processes and to the relativetranslations between the components.

A second aim was to realize an electrical connection in series betweencells of the front-back type called H-type with a lower workingtemperature with respect to the conventional techniques, beingparticularly realized by measuring and laying limited amounts ofconductive adhesive interposed between cells and ribbons to replace thetraditional stringers, never exceeding the maximum temperature presentinside the roller which is generally of 150° C. With respect to theconventional welding processes, where the temperature is generallybetween 200° C. and 300° C., the use of reduced temperatures determinessignificant advantages for the panel and for the materials contained init because the strains and the residual tensions arising inside theribbons are considerably lower. In particular, it has been observed thatthis advantage occurs also for a long time after the assembly phase,extending to the whole operational life of the panel which is thusexposed to lower probabilities of breaking of the cells. Moreover,process temperatures lower than 150° C. allow to use photovoltaic cellswhich otherwise do not bear high temperatures due to their structuralnature such as said cells of the HIT™ or HJT type.

A third aim was to obtain a significant saving of the materials usedsuch as the low-melting alloys applied on the surfaces of the ribbons orpart of the silver paste laid on the busbars of the cells; furthermore,the fingers are reduced and the use of the pre-fixing adhesive tapes iscompletely eliminated.

A fourth aim was to enable the industrial production of photovoltaicpanels with cells of the front-back type in a more automated way withrespect to the traditional processes by considerably reducing the manualinterventions during the phases prior to the rolling and with particularreference to a faster and more precise front-back contacting of thecells, also with a greater guarantee of quality of the product.

A fifth aim, linked to the previous one, was to integrate a controlsystem of the automatic type which checks each working process carriedout during the assembly process, thus increasing the overall level ofquality of production and the repeatability of the product.

A sixth aim was to realize an assembly plant with operating stations ofthe modular type, having a regular geometric shape, compact, repeatable,easy to be combined, each of them being easily equippable according tothe specific working process and with low economic investments;furthermore, said assembly plant occupies a small surface area.

An additional aim was to provide high production flexibility, enablingeasy changes in the configuration of the panel, for example in thequantity, shape, size and arrangement of the cells; furthermore, it ispossible to use cells with front-back contacting of the H-typecharacterised by any design of the surface metallization, both withconventional busbars of the continuous type and, advantageously, of thediscontinuous type.

In particular, the automatic production plant and the assembly methodproposed by the invention have high production capacity and highprecision and accuracy of positioning and fixing of the components, insuch a way that the industrial production of photovoltaic panels isconsiderably more economical, repeatable, safe, with considerabletechnical progress and benefits.

These and other advantages will appear from the following detaileddescription of some preferred embodiments, with the aid of the schematicdrawings enclosed whose details of execution are not to be consideredlimitative but only illustrative.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1a shows, in a front schematic view, a photovoltaic panel of firstgeneration, with standard front-back-contact cells of crystallinesilicon of the H-type, according to the prior art.

FIG. 1b is an enlarged detail of panel of FIG. 1a highlighting the zoneof connection of the front string terminals to the back junction box,according to the prior art.

FIG. 2 shows, in a schematic sectional view, the supporting backsheetwith the first layer of encapsulating material and photovoltaic cells ofthe standard type that are electrically connected in string in thefront-back mode by means of the related interconnecting ribbons,according to the prior art.

FIGS. 3a-b orthogonally show the front (FIG. 3a ) and the back (FIG. 3b) of a standard H-type cell of crystalline silicon with continuous andparallel busbars, according to the prior art.

FIGS. 4a-b orthogonally show the front (FIG. 4a ) and the back (FIG. 4b) of a cell of crystalline silicon with innovative busbars of thediscontinuous type in the form of conductive pads which make theassembly by means of the proposed plant and method particularlyadvantageous.

FIGS. 5a and 5b show, in orthogonal views from the top (5 a) and fromthe side (5 b) in section, the plant according to the invention which ismade up of adjacent workstations, of the modular type.

FIGS. 6a, 6b and 6c show, in axonometric views, the plant according tothe invention where the modular workstations are shown with theprotection panels (6 a) and without said panels (6 b-c) to facilitatethe understanding of the inside, the FIG. 6c ) being an enlarged detailreferring to the single station highlighting the conveying-working meanswith Cartesian robot.

FIG. 6d shows, in a schematic view from the top, the kinematic system ofthe conveying-working means with Cartesian robot as is provided by theinvention, as in FIGS. 5b and 6c ).

FIG. 7 is a simplified diagram of the whole production process of aphotovoltaic panel where the assembly of the components is carried outin an automatic way by means of the plant proposed by the invention,according to an assembly method that provides operating phases (F1-9) ina logic sequence being referred to the single workstations of the plantas in FIGS. 5a-b, 6a -b.

FIGS. 8a and 8b show in detail the operating phases (F1-9) as in saidFIG. 7, with the related sub-phases and check phases, according to thepreferred embodiment of the invention.

FIGS. 9a-i show the panel being worked: preliminary preparation of thebacksheet with holes (9 a), fixing of the conductive inserts (9 b),superimposition of the encapsulating material with pre-cut window (9 c);assembly of the components in the plant: lifting of the window (9 d) asin phase F2, application of the head cross ribbons (9 e) as in phase F2,application of the interconnecting ribbons (9 f) head and bottom row inan alternated series as in phase F3, laying and pre-fixing of the firstrow of cells (9 g) onto said interconnecting ribbons upon laying of ECAas in phases F4-5, measured dispensing of ECA in correspondence of thebusbars (9 h) as in phases F4-5, repetition of the laying and of thefixing by rows in an alternated series of cells with interconnectingribbons (9 i) until the completion of all the strings of the panel as inphases F4-5.

DETAILED DESCRIPTION OF THE INVENTION

The present invention describes an innovative plant (10) (FIGS. 5a-b,6a-d ) with modular operating stations (100A-I) for the automaticassembly of photovoltaic panels (30) with a conventional architecture,with front-back-contact solar cells of the H-type; the invention,therefore, proposes an innovative horizontal assembly system which isbased on a particular production method (20) (FIGS. 7, 8 a-b) optimizedaccording to said plant (10), solving the main problems connected to theconventional systems of assembly and stringing of the cells and alsoenabling high production capacity, with great precision of positioningand fixing of the components. In particular, the invention provides thatsaid cells are connected at low temperature on both sides, in anautomated way, by means of limited amounts of an electrically conductiveadhesive placed punctually according to the procedure in use in theelectronic industry; moreover, it is provided that said cells and allthe contacting elements are pre-fixed on the lower layer ofencapsulating material contextually to positioning, in order to preventrelative translations of the components before the final rolling.

The photovoltaic panels (30) which can be made by the plant (10) andmethod (20) according to the invention have a conventional architecturewith front-back-contact solar cells of crystalline silicon, which arealso called standard or first generation cells. Starting from the backside not exposed to the sun, each panel (30) comprises the followingcomponents: a supporting backsheet (309); a first layer of encapsulatingmaterial (310); said solar cells (300-1) of silicon which, inparticular, can be of the monocrystalline type, polycrystalline type oreven of hybrid technology such as on said HIT™ or HJT cells; a pluralityof longitudinal interconnecting ribbons (302) for connecting in seriessaid cells, the front with the back of the adjacent cell, incorrespondence of the related busbars; the cross ribbons at the head(304) and at the bottom (303) of the panel, for collecting the stringcurrents in correspondence of the zone of connection (305, 307) to theback junction box, through passing-through conductive inserts (308 a-d);a second layer of encapsulating material which frontally encloses cellsand connections; a front glass; a rigid frame (306) which encloses theperimeter of the panel (30); the back junction box. For example see theprior art tables (FIGS. 1, 2).

The invention provides the use of any conventional and known solar cellof the standard type, with front-back contacting on busbars. Forexample, it is suitable to use the cells with continuous and parallelbusbars (313, 315) on both sides (311, 302) such as the known cells ofthe H-type (300), see the prior art tables (FIGS. 3a-b ); as analternative, however, it is preferable to use cells with busbars of thediscontinuous type as the contacting of the punctual type is just assuitable for connections with conductive adhesives laid in smallamounts, however providing a great saving in the use of silver paste onthe front of the cell and said saving sometimes being equal to or higherthan 30% of the generally used amount. It has been observed that such acell configuration allows to obtain greater efficiency during productionalso with an extremely high quality of the finished product,particularly in the case of large production volumes. To this purpose,therefore, the invention proposes a particular family of configurationsof cell (301) particularly advantageous for the assembly by the proposedplant (10) and assembly system, having a plurality of discontinuousbusbars (316 a, 318 a) shaped as small conductive pads, aligned to forma hatched busbar.

In more detail, said discontinuous busbars (316 a, 318 a) consist ofaligned and insulated conductive pads (316 b, 318 b), each padpreferably being of a regular geometric shape of the circular, elliptic,square or rectangular type and having, according to said shape, thediameter or the major axis or the greater side between 0.5 and 1.2 mm.Said conductive pads (316 b, 318 b) of each busbar (316 a, 318 a) areplaced at a reciprocal distance between 5 mm and 15 mm, measured on theexternal edge of the pad, and are electrically connected to each otherby a pair of longitudinal fingers (317 b) having a width between 50microns and 120 microns, measured after the production phase calledfiring, and a height between 10 microns and 20 microns in such a way asto cross and transversely connect the cross fingers (317 a). Saidconductive pads (316 b, 318 b) of each busbar (316 a, 318 a) aretherefore individually joined and connected with ECA to oneinterconnecting ribbon (312) only in correspondence of said busbarformed by the row of aligned pads (316 b, 318 b); said discontinuousbusbars (316 a, 318 a) being in a number between 6 and 15 on each face(311-2) of the cell (301), and preferably between 7 and 10.

Therefore, the following English terms which are commonly used in thephotovoltaic sector in the following of the description have themeanings specified as follows:

-   -   backsheet is the supporting and closing sheet placed at the back        of the panel;    -   busbars are the metallized contacting elements for the        collection of the currents frontally picked-up by the fingers,        being sintered at high temperature, for example between 800 and        the 970° C., on both faces of the cell and of any structure both        continuous and discontinuous;    -   cross ribbons are the electrically conductive cross elements in        the form of ribbons which convey all the string currents in        correspondence of the head and of the bottom of the panel,        towards the junction box;    -   dispensing is the automatic technology of distribution and        punctual and calibrated laying of small amounts of ECA,        generally in single drops, in use in the electronic industry;    -   ECA, the English acronym for electric conductive adhesive, is an        electrically conductive adhesive of the type used in the        electronic sector which is applied punctually in drops with        automatic devices and in precisely measured amounts. For        example, for the purposes of the present invention it is        particularly suitable to use an adhesive based for example on        thermosetting epoxy resin normally charged from 85% to 92% with        conductive metal powder which can be variously made up of metals        (such as Ag, Cu, Sn, Bi and others) or metal alloys;    -   fingers are the metallized thin linear elements which frontally        pick up the currents of electrons generated in the silicon cell        by photovoltaic effect;    -   interconnecting ribbons are the electrically conductive        longitudinal elements shaped like thin ribbons which        interconnect the front of one cell with the back of the adjacent        cell; for the purpose of stability during movements, the        invention provides that said elements are connected with        adhesives of the ECA type also being pre-fixed along with the        cells on the underlying layer of encapsulating material.

The invention provides, in particular, that the electrical connectionsbetween said busbars and said interconnecting ribbons are made at lowtemperature applying punctually limited amounts of ECA by means ofautomatic dispensers, according to the known technology calleddispensing or jetting, the measuring and the punctual laying of said ECAbeing carried out with precision in an automatic way assisted byartificial vision systems. Such a solution completely replaces thetraditional stringers that, for the standard front-back-contact cells,generally provide the welding of the conductive ribbons or providesimilar high-temperature techniques, such as induction with weldingpaste, which are disadvantageous as described above.

In more detail, said ECA is interposed, in measured drops (321), betweenthe surfaces to be contacted such as the front surface of said cells(311) in correspondence of the busbars (313, 316 a) and of theinterconnecting ribbons (302); it is known that this technologydistinguishes the phase of dispensing and laying of the adhesive fromthe following phase of activation of the adhesive component with theconcomitant final hardening. The invention provides that said hardeningphase which definitively fixes the cells and ribbons occurs after theassembly of the panel (30), during the conventional rolling process,that is to say, outside the proposed plant (10), although carrying outsaid activation already during the assembly, that is to say, inside saidplant (10) with localised heating, as described in the following. Inparticular, it is observed that in rolling the temperature of 150° C. isgenerally not exceeded, that is to say, a value about 50° C.-150° C.lower with respect to the conventional and known welding systems; withECA and conventional rolling, therefore, said interconnecting ribbonscan have a simplified structure and be more economical, the typicalcoating with low-melting alloys such as the known Sn—Ag—Pb alloy orother similar alloys not being necessary.

By assembling front-back-contact cells of the H-type, for the purpose ofenabling the interconnection without relative translation of thecomponents and with a high level of industrial automation, it isparticularly provided to carry out during assembly the pre-fixing ofcells (300-1) and interconnecting ribbons (302) on the underlying layerof encapsulating material (310), also with the partial activation ofsaid ECA. Said pre-fixing and said activation are obtained concomitantlyand simultaneously inside the plant (10) by means of selective heatingfrom the top, that is to say, being localised frontally only on someparts of said cells and the related ribbons, jointly to the underlyingencapsulating polymeric material. In particular, it is observed thatsaid selective heating has a double function, adhesive on theencapsulating material and of activation of the polymerization of theresin which composes the conductive adhesive; in this way the ribbonsand/or the groups of cells are fixed to their substrate, preventing anytranslation or rotation in the following processing steps until therolling of the whole module. Said operation of selective heating iscarried out in two different moments: the first time it occursconcomitantly to, or immediately after, the laying of theinterconnecting ribbons (302) to fix the latter to the layer ofencapsulating material (310); the second time it occurs concomitantlyto, or immediately after, the laying of said cells (300-1) in the finalposition above said interconnecting ribbons (302), and in particularafter the laying of the ECA in the suitable contact areas between theribbons (302) and cells.

In more detail, said selective heating can be easily carried out bymeans of heating sources frontally arranged at a short distance from thecell or from the ribbons or descending in proximity to the contact;heating means of industrial use such as infrared lamps or otherwavelength lamps, or heating electrical resistors, are suitable for thepurposes of the invention. Such sources are selected and sized in such away that, by acting from the top downwards on distinct portions of saidcomponents at a distance up to 40 mm, temperatures lower than 150° C.and in any case such as to activate the adhesion to the underlyingencapsulating material (309) are reached on said elements (300-5).Therefore, the invention provides that this operation is fast; it hasbeen observed, for example, that by using lamps having a power between 1kW and 4.5 kW at a distance of about 40 mm from the surface of thecells, or even using electrical resistors or inductors, in such a way asto obtain a temperature between 80° C. and 130° C. in proximity to thesurface of the cells and of the ribbons, the pre-set aims are achievedin a time between 0.5 and 7 seconds. In the preferred embodiment, forexample, said pre-fixing is carried out with infrared lamps of about 4kW at a distance of about 20 mm from the cells for a duration of about 5seconds, obtaining a temperature of about 100° C. on the encapsulatingmaterial and of about 120° C. on the cells frontally, in correspondenceof the ECA interposed between the ribbons and the cells.

The innovative plant (10) (FIGS. 5a-b, 6a-d ) for the automatic assemblyof the panels (30) is substantially an in-line plant made up of singleworkstations (100A-I) of the modular type which are laterally adjacentto each other, in correspondence of the long side, each station (100)being individually shaped as a right-angled parallelepiped of standardshape and size. Laterally, said stations (100) have openings (107) insuch a way as to be horizontally crossed by the conveying line (110)with recirculation of trays (109) which transports along the workingsurface (111) each tray containing the panel being worked to return to alower level (112), under said working surface, to substantially form acontinuous loop production line, also called vertical carousel. In thepreferred embodiment, which is intended to limit as much as possible thespaces of the plant (10), said workstations (100A-I) are modular in theform of a standard parallelepiped having the same height, the same shortside and the long side in different versions, for example a base version(100B-E, H-I) corresponding to the width of said conveying line (110) ofthe tray (109) increased by the space for the loading of theelectrically conductive components, for example the cells, and a secondversion (100A, F, G) which also includes an extension in the form of aside compartment (108) for the automated loading of the long components,such as the backsheet, the front encapsulating layer or the glass.

Each workstation (100) is made up of a load-bearing structure (104),preferably of the frame type, with opaque panels (105) of protection andwith transparent plates (106) for the visual controls. Each stationincludes its own portion constituting said conveying line (110) andalso, in particular, it comprises at least one integrated system ofconveying and working of the components of the type called Cartesianrobot (101) with electronic control, preferably managed by means of thesame logic control unit (117) which supervises the whole plant (10)(FIG. 5b ). Said robot (101) is preferably made up of a Cartesianstructure (102) with moving parts and at least one mobile head (103)intended to be equipped from time to time according to the specificworking process required by the workstation; said mobile head (103), infact, is from time to time equipped with means for the pneumatic loadingand/or for the electrical contacting with ECA and/or for the pre-fixingby localised heating, in such a way as to enable the horizontal assemblyof all the components, by progressive superimpositions on the backsheet(309, 310) which is loaded on the tray (109) with the encapsulatingmaterial (310) facing upwards, forming a panel (30) ready for rolling.In more detail, said Cartesian robot (101) has a structure (102) withroto-translation (118 a-d) of the type with mobile gantry (102 b) onpower-operated rails (102 a) with at least one mobile head (103)equipped to carry out the working processes on the working surface (111,119 a-b) (FIGS. 5b, 6c-d ); in particular, said mobile gantry (102 b) isconstrained to said power-operated rails (102 a) on hinge-sliding blocksindependent in the movement and coordinated with respect to each other(118 a-b) in such a way as to enable the horizontal translation and alsothe rotation (118 d) around the vertical axis, said gantry (102 b) beingof the telescopic type (118 c) and this solution (118 a-d) beingextremely advantageous for the purpose of the automatic alignments. Thekinematic system of said robot (101) is completed by said mobile head(103) which is power-operated at least to translate longitudinally (119a), along the gantry, and also to operate vertically (119 b) (FIG. 6d ).

In more detail, it is provided that each workstation (100A-I) isindividually equipped to carry out different working processes incorrespondence of the particular phase (F1-9) required by the assemblymethod (20), each phase being substantially corresponding to eachworkstation (100A-I) sequentially placed in series, being adjacent andjoined by means of said conveying line (110-2) through said openings(107), in such a way as to allow a plurality of identical trays (109),containing the panels during the assembly phases, to cross all thestations in a continuous way. The trays, therefore, proceed on said line(110) made up of the series of conveyor belts of each station, beingopposite, rectilinear and horizontal and intended to optimize the pathsand eliminate the superfluous sections, to return below when assemblyhas been completed, with loop recirculation (111-2). On each tray thesequentially following operation is carried out from time to time, atthe corresponding station of the plant (10); in some cases, saidoperation is repeated several times, as it occurs for the measureddispensing of ECA or for the laying and the interconnection of the cells(300-1) that are progressively arranged in parallel rows, in such a wayas to perform each operation in the shortest time possible and with theshortest path possible. In correspondence of each station (100),therefore, there is the automatic check of the relative operationperformed. The panels obtained by the plant (10) and the systemaccording the invention are advantageously assembled and checked, readyto be inserted into the traditional rolling furnaces.

To this purpose, said series of operating stations (100A-I) isconfigured in a linear sequence according to a conveying line (110-2) ofthe carousel type with recirculation of trays (109), which crosseshorizontally with a rectilinear path the adjacent stations at a lowerlevel in the form of a loop after the unloading of the panel, comprisingoptoelectronic control devices of the type preferably in correspondenceof each operating station, in such a way as to check the correctness ofthe working processes carried out; said control device enabling theworking or the simple transit of said tray in the following station bycomparison of the actual status with a pre-set status.

In more detail as to the preferential but not exclusive embodiment ofthe invention, said plant (10) for the automatic assembly ofphotovoltaic panels (30) consists of a production line with workstations(100) of the modular type sequentially arranged to progressivelyassemble the panel, each station (100A-I) being equipped to carry out aspecific operating phase (F1-9) according to the proposed automaticassembly system. Said plant (10), comprising (FIGS. 5a-b, 6a-d ):

-   -   a first operating station (100A) including means for the        transfer and locking of the tray (109) and means for the loading        of the backsheet (309), of the Cartesian robot type with vacuum;        the backsheet is already arranged with the encapsulating layer        (310) and passing-through conductive inserts (308 a-d) for the        purpose of the following connection to the back junction box,        after rolling. The backsheet is loaded onto an empty tray (109)        with the encapsulating material facing upwards. Said tray may be        provided with prior art pneumatic and/or mechanical devices        intended for the holding of the backsheet in such a way as to        prevent its movement during the operating phases inside the        various workstations. Said first station, with reference to the        operating phase (F1, F1.0-1.1) (FIGS. 7, 8 a, 9 a-d);    -   a control device consisting of cameras and vision software,        particularly intended to check the operations performed and        calibrate movements. Said device, with reference to the        sub-phase of check (FV1) (FIG. 8a );    -   a second operating station (100B) including means for the        transfer and locking of the tray and means for the laying and        pre-fixing of the head and bottom cross ribbons, upon opening of        the window (320) in the encapsulating material (310), also with        means for the measured dispensing of ECA in correspondence of        the conductive inserts (308 a-d). Said second station with        reference to the operating phases (F2, F2.0-2.7) (FIGS. 7, 8 a,        9 c-e);    -   a control device consisting of cameras and vision software,        particularly intended to check the operations performed and        calibrate movements. Said device, with reference to the        sub-phase of check (FV2) (FIG. 8a );    -   a third station (100C) including means for the transfer and        locking of the tray and means for the laying and pre-fixing of        the first line of interconnecting ribbons (302) near the head        (304) and bottom cross ribbons (303), also with means for the        measured dispensing of ECA. Said third station with reference to        the operating phases (F3, F3.0-3.6) (FIGS. 7, 8 a, f);    -   a control device consisting of cameras and vision software,        particularly intended to check the operations performed and        calibrate movements. Said device, with reference to the        sub-phase of check (FV3) (FIG. 8a );    -   a fourth station (100D) including means for the transfer and        locking of the tray and means for the laying and pre-fixing of        the pre-oriented cells (300-1), one row at a time, to        progressively form alternated strings of cells, with means for        the measured dispensing of ECA, being first laid on the first        row of interconnecting ribbons (302) and then on the front        surface of the cells to subsequently connect the ribbons (302).        Such operations can be repeated several times in said fourth        station to complete the whole covering of the backsheet;        however, for the purpose of shortening the cycle time and        balance the crossing times, such operations can be repeated        simultaneously on several twin stations arranged in line, to        complete in sequence different and complementary zones of the        same backsheet. In the preferential but not exclusive        configuration described herein, the invention provides a        subdivision on two twin stations: in this case said fourth        operating station (100D) lays and fixes the cells with the        related interconnecting ribbons starting from the bottom cross        ribbons (303) covering with alternated strings of cells half of        the surface. Said fourth station, with reference to the        operating phases (F4, F4.0-4.7) (FIGS. 7, 8 a, 9 g-i);    -   a control device consisting of cameras and vision software,        particularly intended to check the operations performed and        calibrate movements. Said device, with reference to the        sub-phase of check (FV4) (FIG. 8a );    -   an optional fifth station (100E), the twin of the previous        fourth station, which realizes the complementary strings of        cells starting from the head cross ribbons (304). Said fifth        station, with reference to the operating phases (F5, F5.0-5.7)        (FIGS. 7, 8 b, 9 g-i);    -   a control device consisting of cameras and vision software,        particularly intended to check the operations performed and        calibrate movements also with the check of the complete assembly        of cells and ribbons. Said device, with reference to the        sub-phase of check (FV5) (FIG. 8b );    -   a sixth station (100F) including means for the transfer and        locking of the tray and means for the loading of the layer of        encapsulating material over the cells and the ribbons previously        placed and pre-fixed. Said sixth station, with reference to the        operating phases (F6, F6.0-6.3) (FIGS. 7, 8 b);    -   a control device consisting of cameras and vision software,        particularly intended to check the operations performed and        calibrate movements. Said device, with reference to the        sub-phase of check (FV6) (FIG. 8b );    -   a seventh station (100G) including means for the transfer and        locking of the tray and means for the loading of the front        glass, to obtain the assembled panel (30). Said seventh station,        with reference to the operating phases (F7, F7.0-7.1) (FIGS. 7,        8 b);    -   a control device consisting of cameras and vision software,        particularly intended to check the operations performed and        calibrate movements. Said device, with reference to the        sub-phase of check (FV7) (FIG. 8b );    -   an eighth station (100H) including means for the transfer and        locking of the tray and means for its overturn along with the        panel, turning the glass downwards in a position suitable for        the outcoming on the belt, towards the rolling furnace, also        with means for the release of the tray from the panel and for        the counter-overturn of the same tray made empty. Said eighth        station, with reference to the operating phases (F8, F8.0-8.2)        (FIGS. 7, 8 b);    -   a ninth station (100I) including means for the recirculation and        for the return onto a lower sliding level of the tray made empty        towards the first station (100A). Said ninth station, with        reference to the operating phases (F9A, F9A.0-9A.1) (FIGS. 7, 8        b); said ninth station (100I) also includes means for enabling:        the extraction of the tray with the non-compliant panel for        possible reprocessing, or to reinsert the tray containing the        reprocessed product, or also to reinsert an empty tray. Should        at least one of said control devices between the previous        stations give a negative result about the correctness of the        operation performed, said ninth station is reached directly        without said overturn of the tray, that is to say, enabling the        simple transit in the intermediate stations. Said ninth station,        with reference to the operating phases (F9B, F9B.0-9B.2) (FIGS.        7, 8 b);    -   a main conveying line (110) with recirculation of trays (109),        of the type with conveyor belts included in each station, with a        total loop path which crosses said stations (100A-I)        horizontally in a straight line and returns to a lower level        (112) with respect to the working surface (111), always within        the dimensions of the plant (10). The circulation can be        indifferently in one direction or in the opposite one according        to the cycle of sequence of the operations provided; the line,        in fact, can work indifferently with a flow of the trays from        right to left or vice-versa without particular arrangements or        changes;    -   a logic control unit (117), programmable, of the PLC type which        supervises the whole plant in an integrated way.

Said plant (10,100A-I) therefore allows, according to the industrialproduction choices, to assemble the panel (30) indifferently startingfrom a backsheet provided with encapsulating material, as describedabove, or as an alternative starting from the front glass on which alayer of encapsulating material is laid, then one carries out saidapplication sequence with head and bottom cross ribbons, first row ofinterconnecting ribbons, the cells with the related interconnectingribbons in alternated series repeated until the completion with thefinal interconnecting ribbons, and on which one places the backencapsulating material and a backsheet provided with conductive inserts,which connect to said head cross ribbons; in that case, the overturnbefore rolling is not necessary. Said plant also allows, according tothe industrial production choices, to increase or reduce the number oftwin stations (100D-E) for the purpose of adapting to the requiredproductivity, or it also allows to change the sequence of the operationsin said twin stations.

In more detail as to said movement system (110) with recirculation ofthe trays (109), a configuration is preferably provided, whichcomprises: a first transport path preferably of the conveyor belt typewhich horizontally moves the trays from one station to the other on theworking surface (111) consecutively from the first one (100A) to thelast one (100I); a programmable logic control unit (117), of the PLCtype, also integrated to the whole plant, which supervises the overallmovement of each tray, for example being called by the downstreamstation (100I) when this has completed its operation; a descender devicewhich from time to time lowers each tray which reaches the end of theline (114); a second transport path on the recirculation surface (112)of the conveyor belt or roller conveyor type which horizontally, but ona lower level than the first one, moves the trays from the last station(100I) to the first station (100A); a lifter device which lifts to thelevel of the first transport path from time to time each tray whichreaches the start of the line.

In more detail as to said first station (100A), it is provided that thebacksheet (309) has been previously coupled with the layer ofencapsulating material (310) in such a way that it is opposite to theback surface of the photovoltaic cells (300-1), therefore facing upwardsin the tray; said encapsulating material preferably consists of athermosetting or thermoplastic material, such as polyolefins or siliconeor polyvinyl butyral, or of a cross-linking material, like said EVA,which is thermally fixed or fixed by gluing onto the backsheet itself.Before adding said layer of encapsulating material, the backsheet can beadvantageously prepared to facilitate the electrical connection to thejunction box which is joined at the back to the panel after the rollingphase (202); this preparation can also occur prearranging conductiveinserts (308 a-d) within holes (319 a-d) open in correspondence of theclamps of the back junction box (FIGS. 9a-c ). This preparation canoccur according to known techniques such as, as a non-exhaustiveexample, those described in ITTV2013A000059 (Baccini), ITTV2013A000060(Baccini), ITTV2013A000193 (Baccini) or any solution of the automatictype which is intended to integrate in the backsheet interfaceconductive elements, like conductive pads, in such a way as tofacilitate the electrical connection of the terminal points of thecircuit to the back junction box.

In said first station (100A), said backsheet (309, 310) is preferablypicked out of a pile arranged on a pallet placed in the picking-up zone(108) by the Cartesian robot (101) being provided with a vacuum devicein the mobile head (103), with a picking hand which picks up one singlebacksheet and transports it into the working zone on the tray (109),also checking its orientation by means of said control device whichsubstantially consists of a vision system comprising cameras andposition recognition software. This recognition allows the programmableunit which manages the movement along the axes of said robot (101-2), byan algorithm, to orient it in such a way as to lay on the empty tray, inan oriented and repeatable way, said backsheet (309) randomly pickedfrom the pallets in said picking-up zone (108). Said tray (109), inparticular, can be provided with conventional means for holding thebacksheet during the following assembly phases, for example of the typewith automatic pushers. Moreover, said tray is advantageously providedwith an identification code and with reference signs in such a way thatthe backsheet, besides being fixed in a pre-set position, can besubsequently monitored by the following control devices for possiblecompensations of the coordinates after the various operating phases. Theinvention allows to assemble on each tray a photovoltaic panel havingstandard sizes widespread on the market; in particular, it isparticularly advantageous in the case of panels made up of 48 cells, or60 cells or even 72 cells, arranging them in horizontal and repeatedrows of 6 cells each, not requiring any physical re-fitting but only aselection of general software arranged for sequences of operationsrelated to the assembly of a panel made up of 48 cells, or 60 cells, or72 cells.

In more detail as to said second station (100B), the proposed assemblysystem provides that after the arrival and the locking of the tray inthe pre-set position a window (320) is opened in the sheet ofencapsulating material (310) in correspondence of said metal inserts(308 a-d) already included (FIGS. 9c-d ); this zone is advantageouslypre-cut in the sheet and left free, that is to say, not fixed on thebacksheet for the purpose of enabling its opening. Furthermore, in saidstation a small amount of ECA is laid onto the conductive inserts bymeans of the automatic dispenser, being exactly measured for contacting.Afterwards, the head (304) and bottom cross ribbons (303), alreadyprepared and cut to size (FIG. 9e ), are laid by means of Cartesianrobots. This positioning is carried out with precision thanks to saidvision system with dedicated software which is integrated with thecontrol of the movement axes of said Cartesian robot (101). Therefore,in this way one realizes the electrical continuity between theconductive inserts (108 a-d) of the backsheet and said head crossribbons (304).

Said cross ribbons (303-4) are advantageously pre-fixed concomitantly totheir positioning; to this purpose, the same picking hand which holdsthem in the correct position in contact with the layer of encapsulatingmaterial can advantageously integrate means for the selective heatingplaced at the correct distance, as described above, realizing saidpre-fixing on the encapsulating material. It is observed, in particular,that said conductive elements (302-4) are excellent electrical andthermal conductors and therefore enable a fast and effective heating ofthe underlying encapsulating material, activating its adhesive feature.Said heating is preferably carried out for a time between 2 and 5seconds, with temperatures between 70° C. and 130° C. Said window (320)is then closed, preferably with the marking operation of the type calledtagging.

In more detail as to said third station (100C), after the arrival andlocking of the tray in the pre-set position by means of an automaticdispenser a small amount of ECA is laid onto said head and bottom crossribbons, in the form of perfectly measured single drops; afterwards, bymeans of Cartesian robots for industrial use, one lays the first row ofinterconnecting ribbons (302) prepared and cut to size (FIG. 9f ). Inparticular, it is observed that said positioning is of high precisionthanks to the vision system and to the software which interact with thecontrol of the movement axes of the Cartesian robot (101). In this wayone realizes an electrical continuity between the head and bottom crossribbons previously fixed in the backsheet with the longitudinalinterconnecting ribbons. Said ribbons (302) are fixed on theencapsulating material preferably concomitantly to their laying, bymeans of a pre-fixing system substantially equal to the above-describedsystem and integrated in the previous station. At the end, the controldevice checks the correct execution of the operation.

In more detail as to said fourth station (100D), after the arrival andthe locking of the tray (109) in a pre-set position, a measured amountof ECA is laid onto the interconnecting ribbons (302) already laid, withthe same dispensing system as the previous station; afterwards one takesfrom a specific loading station by means of Cartesian robots a series of6 solar cells which are laid 3 by 3 in an alternated sequence on thetray in such a way that the previously laid and fixed head and bottominterconnection strings match the busbars situated on the back faces ofthe cells (FIG. 9g ).

On said series of cells the related interconnecting ribbons (302) canhave been previously prepared, cut to size, suitably shaped and fixed onthe front of the cells in such a way as to adhere with precision to thefront busbars (313, 315), or they can be mounted on said busbars (313,316) situated on the front faces of the cells after these have beenassembled and laid on the layer of encapsulating material (310) in thetray (109) upon measured dispensing of ECA on the front busbars of saidcells, with the same dispensing system as the previous stations (FIG. 9h). Said cells reach the fourth station (100D) generally stacked inboxes, or racks, and from these they are individually extracted orpicked up, pre-oriented on feeding belts from which they are picked upby the anthropomorphic or Cartesian robots to be laid in the workingzone individually or in multiple series. Therefore, a similar pre-fixingis carried out, as described above, after the laying of the cells on theencapsulating material (310) and in correspondence of said alreadypre-fixed interconnecting ribbons; said pre-fixing being preferablyconcomitant to the laying of the cells. The control device consisting ofthe cameras and vision software allows to check the correct execution ofthe operation and the correct arrangement of cells and strings.

In more detail as to the completion of all the cells and theinterconnections of the panel, it is observed that said sequence ofoperations for the laying and pre-fixing of the strings of solar cellslaid in parallel rows on the first layer of encapsulating material(310), with the related interposed interconnecting ribbons (302), beingin their turn fixed upon measured dispensing of ECA from time to timeinterposed between cells (300-1) and ribbons (302), must be repeatedseveral times in sequence in the fourth station (100D), until thecompletion of the whole panel. As an alternative, also to shorten thecycle time balancing the crossing time between the stations, said fourthstation can be advantageously repeated in one or more contiguous twinstations, similarly equipped to complete in sequence different andcomplementary zones of the same backsheet.

To this purpose, in an advantageous and preferred configuration of theinvention (10, 20), the laying of each string of cells and relatedinterconnecting ribbons is carried out in a combined way in two twinstations, identical to each other and arranged in sequence, toprogressively fill in sequence two different and complementary zones ofthe same backsheet; in this case said fourth station (100D) is repeatedin a fifth station (100E) constructively identical to said fourthstation, which is programmed to lay in rows cells and interconnectingribbons only in correspondence of half of the strings of cells,alternated with respect to each other, while said fifth station (100E)covers the second half in an alternated and complementary way, untilcompleting the whole panel (FIG. 9g-i ). The invention (10, 20) alsoenables alternative assembly sequences in said fourth (100D) and fifth(100E) station, or further twin stations equally intended for theassembly of cells and interconnecting ribbons, for example it beingpossible to start the loading indifferently from the head or from thebottom of the panel.

The last row of interconnecting ribbons (302) is directly connected tothe head (304) and bottom cross ribbons (303) to complete the electriccircuit of all the strings of cells connected in series, with the endsof the circuit directly on the metallic inserts (305, 307, 308 a-d),being ready for the connection to the back junction box.

In more detail as to the sixth station (100F), after the arrival andlocking of the tray in a pre-set position, the front layer ofencapsulating material is laid to cover the cells previously placed withthe related interconnections; said encapsulating material preferablyconsists of a thermosetting or thermoplastic material, such aspolyolefin, silicone or PVB, or it is a cross-linking material likecommonly EVA, which can advantageously be unwound from a reel situatedin proximity to said sixth station and cut into sheets of the sizesuitable for the surface of the panel being worked. The sheet of frontencapsulating material can advantageously be taken and laid by theabove-described Cartesian robot system. The control device allows tocheck the correct execution of the operation.

In more detail as to the seventh station (100G), after the arrival andlocking of the tray in a pre-set position the front glass is laid tocover and complete the panel; said glass can advantageously be picked upfrom of a pile arranged on a pallet in proximity to said seventhstation, in a specific position so as to be able to be advantageouslypicked up and laid by the above-described Cartesian robot system. Thecontrol device allows to check the correct execution of the operation.

If the assembled panel is compliant, it proceeds up to the eighthstation (100H) where, after the arrival and locking of the tray in apre-set position, the overturn of the tray containing the panel iscarried out, without offsetting of the single components contained in itthanks to the controlled pressure of pushers which enclose and press theglass onto the tray during the whole 180° revolution, with the rotationaxis placed parallel to the major side of the tray orthogonal to thedirection of advancement of the tray, until the positioning of saidpanel in the most suitable position for the outcoming from the plant(10), that is to say, with the glass facing downwards sliding laterallyon a belt conveyor (115), upon release of said tray from the panel bymeans of the pressers which are pulled back, for the purpose of sendingthe panel towards a conventional rolling furnace. Said overturn iscarried out in such a way as to allow in any case in each of itspositions of start or end of the overturn the transit of the trays onthe lower return path in order to never interrupt the recirculation ofthe trays, if not exclusively during the actual rotation. After theoutcoming of the panel, in said eighth station one carries out acounter-rotation in the opposite direction of the tray made empty forthe purpose of replacing it in its original arrangement. If, on theother hand, the panel is non-compliant with one of the check phasespreviously performed (FV1-7) (FIGS. 8a-b ), in said eighth station the180° rotation is not carried out but one passes directly to the laststation.

In the ninth and last station (100I), if said compliant panel has comeout of the eighth station (100H), the tray made empty descends to alower sliding level for the return to the first station (100A) throughthe underlying recirculation system (112). If, on the other hand, theassembled panel is non-compliant, it proceeds directly into said ninthstation (100I) along with the tray for the controls and the possiblereprocessing, getting out of the line (10) in an orthogonal direction(116), on a specific path with belts or on trolley or other supportingdevice, and also re-entering after such controls and/or reprocessing(FIGS. 6b, 8b ). From the latter station it is therefore possible fromtime to time to: extract the tray containing the non-compliant productfor the necessary reprocessing, or reinsert the tray containing thereprocessed product for the following possible necessary operations, oralso reinsert an empty tray.

In more detail as to the logic of the checks, it has been observed thatin the case in which at least one of the controls performed in thepassages between said stations has given a negative result as to thecorrectness of the operation previously carried out, the logic controlunit (117) which manages in an integrated way all the operations of theautomatic assembly plant (10) will enable the simple transit of the traywith its contents in the following stations until it reaches said laststation (100I), without being subjected to the overturn of said eighthstation (100H).

Said plant (10, 100A-I), made as described above, follows the operatingsequence provided by the automatic assembly method (20) provided by theinvention; said method improves the whole production process (200) ofthe panel (30) which thus provides: the preliminary preparation of thebacksheet with conductive inserts and layer of encapsulating material,according to known techniques, the automated assembly in said plant (10,100A-I) according to the innovative method (20), the final rolling inconventional furnaces (202) and the assembly of the back junction boxand of the frame (203). Said method (20), in particular, optimizes theassembly of the components with an automatic cycle made up of sequentialworking phases which horizontally forms a panel already ready forrolling, without handling. Said method (20) comprises the followingOperating phases (F1-9B) (FIG. 7) and related sub-phases (FIGS. 8a-b )with Check phases (FV1-7):

-   -   Operating phase (F1) of loading of the backsheet (309) on the        tray (109) having been previously prepared with the        encapsulating material (310) and optionally with inserts (108        a-d), in the station (100A) (FIGS. 9a-c ) and with the related        sub-phases: F1.0) transfer and locking of the tray from the        recirculation level (112) to the working level (111); F1.1)        loading of the backsheet prepared on the tray; FV1) check.    -   Operating phase (F2) of application of the head (304) and bottom        cross ribbons (303), in the station (100B) (FIGS. 9d-e ) and        with the related sub-phases: F2.0) transfer and locking of the        tray from the previous station; F2.1) laying of the bottom cross        ribbons (303); F2.2) pre-fixing of the bottom cross ribbons;        F2.3) opening of the window (320) of the encapsulating material        (310); F2.4) measured dispensing of ECA on the inserts (108        a-d); F2.5) laying of the head cross ribbons (304); F2.6)        pre-fixing of the head cross ribbons; F2.7) closing and tagging        of the window of the encapsulating material; FV2) check.    -   Operating phase (F3) of application of the first row of head and        bottom interconnecting ribbons (302), in the station (100C)        (FIG. 9f ) and with the related sub-phases: F3.0) transfer and        locking of the tray from the previous station; F3.1) measured        dispensing of ECA on the bottom cross ribbons; F3.2) laying of        the bottom interconnecting ribbons in an alternated series;        F3.3) pre-fixing of the bottom interconnecting ribbons; F3.4)        measured dispensing of ECA on the head cross ribbons; F3.5)        laying of the head interconnecting ribbons in an alternated        series; F3.6) pre-fixing of the head interconnecting ribbons;        FV3) check.    -   Operating phase (F4) of laying of the cells (300-1) and        interconnecting ribbons (302) from the bottom in alternated and        repeated series to complete half of the cover, in the station        (100D) (FIGS. 9g-i ) and with the related sub-phases: F4.0)        transfer and locking of the tray from the previous station;        F4.1) measured dispensing of ECA on the first row of        interconnecting ribbons from the bottom; F4.2) laying of the        cells on the first row, in an alternated series (FIG. 9g );        F4.3) pre-fixing of the row of cells on the ribbons; F4.4)        measured dispensing of ECA on the row of cells (FIG. 9h ); F4.5)        laying of the interconnecting ribbons on the row of cells; 4.6)        pre-fixing of the row of cells and ribbons; F4.7) repetition        from F4.1 for each following row (FIG. 9i ); FV4) check.    -   Operating phase (F5) of laying of the cells (300-1) and        interconnecting ribbons (302) from the head in alternated and        repeated series in a complementary way with respect to the twin        station, in the station (100E) (FIGS. 9g-i ) and with the        related sub-phases: F5.0) transfer and locking of the tray from        the previous station; F5.1) measured dispensing of ECA on the        first row of interconnecting ribbons from the head; F5.2) laying        of the cells on the first row, in an alternated series (FIG. 9g        ); F5.3) pre-fixing of the row of cells on the ribbons; F5.4)        measured dispensing of ECA on the row of cells (FIG. 9h ); F5.5)        laying of the interconnecting ribbons on the row of cells; F5.6)        pre-fixing of the row of cells and interconnecting ribbons;        F5.7) repetition from F5.1 for each following row (FIG. 9i );        FV5) check.    -   Operating phase (F6) of laying of the upper layer of        encapsulating material, in the station (100F) and with the        related sub-phases: F6.0) transfer and locking of the tray from        the previous station; F6.1) unwinding of the sheet of upper        encapsulating material; F6.2) cutting; F6.3) picking and laying;        FV6) check.    -   Operating phase (F7) of laying of the front glass, in the        station (100G) and with the related sub-phases: F7.0) transfer        and locking of the tray from the previous station; F7.1) picking        and laying of the glass; FV7) check.    -   Operating phase (F8) of overturn of the panel if compliant, in        the station (100H) and with the related sub-phases: F8.0)        transfer and locking of the tray from the previous station;        F8.1) overturn of the panel and counter-overturn of the tray;        F8.2) outcoming on the belt with the glass facing downwards.    -   Operating phase (F9A) of recirculation of the empty tray, in the        station (100I) and with the related sub-phases: F9A.0) transfer        and locking of the tray from the previous station; F9A.1)        descent of the tray and return to the tray recirculation level.    -   Operating phase (F9B), alternative to the Operating phase (F9A)        in the station (100I), unloading of the tray with the panel if        non-compliant and with the related sub-phases: F9B.0) transfer        and locking of the tray from the previous station; F9B.1)        outcoming of the tray with the panel for analysis and/or        reprocessing purposes; F9B.2) incoming of the tray with the        panel after analysis and/or reprocessing.

It has been observed that the characteristics of the above-describedplant (10), comprising the single operating stations (100A-I), as wellas the characteristics of the above-described method (20) can be easilyadapted according to the specific application configuration, for exampleto assemble photovoltaic panels with non-standard sizes orconfigurations or cell arrangement or for cells with a particularmetallization. Furthermore, for the purpose of lowering industrial costsalso saving the space occupied by the plant (10) and the relatedinvestment, it is provided that some of the above-described phasesinstead of being carried out in different stations, as explained abovefor the sake of descriptive simplicity, may advantageously beconcentrated and/or integrated in a smaller number of stations thoughkeeping unchanged the single functions of the plant and the logicsequence of the automatic assembly method; for example, the functions ofsaid fourth and fifth stations can be performed by one station only withlower plant productivity, or the functions of said sixth and seventhstations or still of the eighth and ninth stations can be concentrated,however lengthening the total cycle time.

Moreover, it has been observed that by the above-described plant (10)and system (20) it is possible to obtain great precision andrepeatability over the whole working area corresponding to the entiresurface of the tray and particularly of the panel, both of the measureddispensing of ECA and of the positioning of the cells and of the relatedinterconnecting ribbons; such an advantage provides an innovative designapproach to the construction of the panel (30) and also to the surfacemetallization of the photovoltaic cells (300-1); in particular, themetallization surface of the busbars (313, 315, 316, 318) can be reducedalso with a significant saving of costs, as described above. As anon-exhaustive example (FIGS. 4a-b ), said busbars (316, 318) can beoptimized limiting the metallization surface exactly to the surfacewhere the drops of ECA are applied punctually, with the double advantageof reducing the expensive silver paste as well as of reducing the widthof said interconnecting ribbons (302) with less shading. Furthermore, itis also possible to increase the number of said busbars as there are notthe known construction and dimension limits of the conventionalstringing systems; in this way the metallization grid of the cell frontcan be of further use for the consequent possible reduction in theheight and volume of the fingers (314, 317), which can thus become muchthinner and more numerous transporting over a smaller length equal orgreater current. Hence results an important saving of expensivematerials and lower operating difficulties with respect to therealization of the conventional narrow and thick fingers, also with lesswastes and greater energy conversion efficiency both of the cells and ofthe assembled panel. To summarize, therefore, the present inventionsimplifies and makes more economical the manufacturing process ofphotovoltaic cells as well.

It has been ascertained that the present invention, in its basicconfiguration described herein, allows to obtain an equivalentproduction capacity between about 60 MW/year and 90 MW/year, accordingto the power and to the number of solar cells of each panel, whichcorresponds to about 270,000 panels/year, expandable in a progressiveand modular way; such a result is in any case already considerablygreater with respect to the conventional and known plants, whichmoreover have the drawbacks solved by the present invention. Theproposed plant (10) and method (20), moreover, have a high applicationflexibility as they can be configured in such a way as to increase ordecrease said production capacity according to the specific industrialapplication.

Therefore, it has been observed in the practice that the invention hasachieved the above-mentioned task and aims realizing an automaticassembly plant (10) and method (20) which provide important advantagesfor the production of photovoltaic panels (30) in terms of costs,performances, quality and duration and therefore is an importantcontribution to the advantageous and convenient availability ofrenewable power sources.

REFERENCE

-   -   (10) Automatic production plant with modular and aligned        operating stations for the assembly of photovoltaic panels with        cells of crystalline silicon connected at low temperature;    -   (100) workstation of the modular type, (100A) first station of        loading on the tray of the backsheet already prepared with        conductive inserts and first layer of encapsulating material,        (100B) second station of application of the head and bottom        cross ribbons, (100C) third station of application of the        interconnecting ribbons referred to the first head and bottom        row, (100D) fourth station of laying of the cells and of the        related interconnecting ribbons following an arrangement in an        alternated and repeated series starting from the bottom, (100E)        fifth station twin of the fourth station starting from the head,        (100F) sixth station of loading of the front layer of        encapsulating material, (100G) seventh station of laying of the        front glass, (100H) eighth station of overturn of the assembled        panel, (100I) ninth station of separation of the panel if        compliant or of deviation if non-compliant;    -   (101) Cartesian robot;    -   (102) structure of the robot with mobile gantry (102 b) on        power-operated rails (102 a);    -   (103) mobile head to be equipped according to the working        process;    -   (104) load-bearing frame of the workstation;    -   (105) protection panel;    -   (106) transparent plate for visual control;    -   (107) opening for the incoming-outcoming of the conveying line;    -   (108) side compartment of loading of the long components;    -   (109) tray;    -   (110) carousel conveying line with recirculation of the trays        formed by the portions of line comprised in each station;    -   (111) upper level working surface with tray advancement;    -   (112) lower level of tray recirculation;    -   (113) start of the line, upstream of the plant;    -   (114) end of the line, downstream of the plant;    -   (115) outcoming of the compliant panel, with the glass facing        downwards;    -   (116) outcoming of the tray with the non-compliant panel and        incoming of the tray with the reprocessed panel;    -   (117) programmable control logic unit, of the PLC type, which        supervises the whole plant in an integrated way;    -   (118) movements of roto-translation of the Cartesian robot, the        gantry being constrained to the side rails with independent and        coordinated hinge-sliding blocks (118 a-b) and telescopic (118        c) in such a way as to enable the rotation around the vertical        axis (118 d);    -   (119) movements of the mobile head, with translations (119 a)        along the gantry and vertical movements (119 b) for the purposes        of the working processes;    -   (20) automatic horizontal assembly method with connections at        low temperature and pre-fixing, as provided by the invention;    -   (200) complete process for obtaining the finished product;    -   (201) preparation of the backsheet with conductive inserts and        encapsulating material, according to known techniques;    -   (202) rolling, according to known techniques;    -   (203) assembly of the box and frame, according to known        techniques;    -   (30) photovoltaic panel with front-back-contact cells;    -   (300) front-back-contact photovoltaic cell of crystalline        silicon of the known and conventional type;    -   (301) front-back-contact photovoltaic cell of crystalline        silicon optimized for the assembly by the plant and system        proposed by the invention;    -   (302) longitudinal interconnecting ribbons or string for the        front-back electrical interconnection between adjacent cells;    -   (303) bottom cross ribbons or string of general connection on        the bottom of the panel;    -   (304) head cross ribbons or string of general connection on the        head of the panel;    -   (305) element of connection to the conductive inserts in        correspondence of the back junction box;    -   (306) frame;    -   (307) zone of connection to the back junction box;    -   (308 a-d) conductive inserts for back junction box;    -   (309) supporting backsheet;    -   (310) layer of encapsulating thermoplastic material;    -   (311) exposed face of the cell, with negative polarity;    -   (312) covered face of the cell, with positive polarity;    -   (313) front busbar of the continuous type on which a string of        the interconnecting ribbon type is superimposed and electrically        connected;    -   (314) fingers for busbars of the continuous type;    -   (315) back busbar of the continuous type;    -   (316 a) front busbar of the discontinuous type in the form of        hatching being made up of aligned conductive pads (316 b);    -   (317 a) cross fingers for conductive pads;    -   (317 b) longitudinal fingers for conductive pads;    -   (318 a) back busbar of the discontinuous type in the form of        hatching being made up of aligned conductive pads (318 b);    -   (319 a-d) holes for conductive inserts;    -   (320) pre-cut window on encapsulating layer;    -   (321) measured drops of ECA;    -   (F1-F9) Operating phases of the assembly with the related        sub-phases (F1.0-F9B.2) and Check phases (FV1-7).

I claim:
 1. An apparatus for automatic assembly of photovoltaic panelshaving H-type solar cells with front-back connections, the apparatuscomprising: a plurality of workstations that are each modular and shapedas right-angled parallelepipeds, said plurality of workstations beingsequentially arranged in a linear series, said plurality of workstationsadapted for progressively assembly of the photovoltaic panel within atray, said plurality of workstation being crossed with a continuousconveying line that recirculates the tray, said plurality ofworkstations each being adjacent at least one side opening so as to becrossed by said continuous conveying line, each of said plurality ofworkstations comprising a Cartesian robot with a mobile gantry that isroto-translable on power-operated rails and having at least one mobilehead, said mobile gantry constrained to said power-operated rails so asto enable both horizontal translation and rotation around a verticalaxis, said mobile head being translatable horizontally along alongitudinal axis of said mobile gantry and also translatablevertically, said mobile head adapted to pneumatically load or dispenseelectrical contact material so as to enable horizontal assembly byprogressive superimpositions of the backsheet with the layer ofencapsulating material facing upwardly so as to form the photovoltaicpanels, said plurality of workstations from upstream to downstreamprogressively comprising: a first station adapted to load theencapsulating material on the tray with the backsheet; a second stationadapted to apply cross-ribbons with ECA; a third station adapted toapply a first row of interconnecting ribbons with ECA; a fourth stationadapted to lay the H-type solar cells in rows and rows ofinterconnecting ribbons in alternating and repeating series; a sixthstation adapted to lay a front encapsulating material; a seventh stationadapted to lay a front glass; an eight station adapted to overturn andoutput the photovoltaic panel; and a ninth station adapted torecirculate the tray when the tray is empty; and a controllercooperative with at least some of said plurality of stations so as tocheck on and to calibrate movements, said controller having cameras andvision software electrically integrated with a logic control unit. 2.The apparatus of claim 1, said controller comprising: a first controldevice between said first and second stations; a second control devicebetween said second and third stations; a third control device betweensaid third and fourth stations; a fourth control device between saidfourth and sixth stations; a fifth control device between said six andseventh stations; and a sixth control device between said seventh andeighth stations.
 3. The apparatus of claim 1, said first station adaptedto transfer and lock the tray so as to load the backsheet having thelayer of an encapsulating material thereon.
 4. The apparatus of claim 1,said second station adapted to transfer and lock the tray and adapted toload a head cross-ribbon and a bottom cross-ribbon upon opening a windowin the layer of encapsulating material, said second station adapted tomeasure the dispense ECA in correspondence to the conductive inserts. 5.The apparatus of claim 4, said third section adapted to transfer andlock the tray and to lay the first row of interconnecting ribbonsadjacent to the head cross-ribbon and the bottom cross-ribbon.
 6. Theapparatus of claim 1, said fourth section adapted to lay the H-typesolar cells one row at a time so as to progressively form alternatingstrings of the ribbons and to subsequently connect the ribbons to afront surface of the H-type solar cells.
 7. The apparatus of claim 1,said plurality of workstations further comprising: a fifth stationadapted to form complementary strips of the H-type solar cells startingfrom the head cross-ribbon in correspondence with a head of thephotovoltaic panel.
 8. The apparatus of claim 1, said sixth stationadapted to transfer and lock the tray, the first encapsulating materialbeing an upper layer of the encapsulating material.
 9. The apparatus ofclaim 1, said eighth station having a belt cooperative therein, saideighth station adapted to place the front glass downwardly upon saidbelt, said belt extending to a rolling furnace, said eighth stationadapted to release the tray from the photovoltaic panels.
 10. Theapparatus of claim 1, said ninth station adapted to recirculate and toreturn the tray on a lower sliding level towards said first station,said ninth station adapted to extract the tray having a non-complaintphotovoltaic panel therein.
 11. The apparatus of claim 1, said mobilegantry being telescopic, said mobile gantry being constrained to saidpower-operated rails on hinge-blocks coordinated with one another so asto enable the horizontal translation and the translation around thevertical axis.
 12. The apparatus of claim 1, further comprising: aconveying line extending between said plurality of workstations, saidconveying line selected from the group consisting of rails, conveyorbelts, and roller conveyors.
 13. The apparatus of claim 1, wherein atleast one of said plurality of workstations has a vacuum sucker so as toautomatically load or unload a component being processed within theworkstation.
 14. The apparatus of claim 1, where in at least one of saidplurality of workstations has a dispenser of a conductive adhesive thatis adapted to calibrate the conductive adhesive in drops at atemperature less than 150° C.
 15. The apparatus of claim 1, wherein atleast one of said plurality of workstations has a pre-fixer that joinsat least one portion of the electrically conductive elements with thelayer of encapsulating material, said pre-fixer being a lamp orelectrical-resistor heater, said pre-fixer acting from a top positiondownwardly on different portions of the electrically conductive elementsat a distance of between 0 mm to 40 mm so as to activate adhesive ontothe underlying encapsulating material.
 16. The apparatus of claim 1, thephotovoltaic panel having discontinuous busbars, the discontinuousbusbars having multiple aligned and insulated conductive pads, each ofthe pads being of a regular geometric shape and having a diameter ormajor axis or greater side with a length of between 0.5 mm and 1.2 mm,the pads being placed at a reciprocal distance of between 5 mm and 15 mmas measured on an external edge of the pad, the pads being connected toeach other by a pair of longitudinal fingers each having a width ofbetween 50 microns and 120 microns and having a width of 10 microns and20 microns, said pair of longitudinal fingers cross and transverselyconnect with other cross fingers, the pads in a common row beingindividually joined and connected with ECA to only one of theinterconnecting ribbons and placed in correspondence with thediscontinuous busbar, said discontinuous busbar being made up of astring of aligned pads, said discontinuous busbars being in a number ofbetween 6 and 15 on each face of the solar cell.